Ducati 1098 Racing Baffles Installation

 

Steps for disassembly, packing and reassembly of Ducati slip-on's: Read instructions fully before starting. Give yourself time to complete; you don’t want to damage anything on your bike. We do not guarantee proper installation. Install at your own risk.

Tools needed for completion:

  • 3/16 Titanium drill bit (make it 2 just incase you break one)
  • Corded drill (most cordless do not provide enough power)
  • Allen Wrenches
  • Hammer and rubber mallet
  • Safety glasses
  • Rivet Gun
  • Dremel w/ cutting bit or grinder
  • Screw drivers
  • Misc. socket sizes
  • Utility knife

 

 *Note: Before you start mark the directions of the removed caps so you can put the muffler back together correctly.


* Before starting make sure you mark the directions on the end cap and back end of muffler so you reassemble it correctly.

1. Remove both mufflers from the bike. Drill out all the end cap rivets using a 3/16" titanium drill bit.

2. Drill out all the rivets on the back end using 3/16" Titanium Rivet.

3. Mark the back end of muffler as seen in photo below before removing from muffler can.

4. Using either a chisel or flat head screw driver and mallet, knock out the back end of the muffler as seen in photos below.

5. Once the back end is removed, use a hammer and knock out the OEM baffle as seen in photo below.

6. Measure .5 inches from the lip of the baffle (where the rivet holes are) and mark all the way around the OEM baffle.

7. Using a grinder or dremel tool, cut off the end cap as seen in photo below. Be careful not to cut yourself on the metal. It will be very sharp.

8. Now grab the back end of the muffler. It is now time to remove the cats.

9. Using either a grinder or dremel tool, cut along the outer cat sleeve as seen in photo below.

10. Use a chisel/flat head screw driver and a hammer and pry out the cat as seen in photo below.

11. Insert the round end of the baffle into the muffler end to insure it fits. There may be parts of the cat left inside that will keep the baffle from sliding in all the way.

16. Reinstall the back end the muffler into the muffler can as seen in photo below. You may need to use a rubber mallet to help. *Be sure you install the back end in the correct direction. Use the line you drew earlier as reference.

17. Reinstall the metal band and muffler end with the provided rivets.

18. Now open the pack of fiberglass repacking and grab one of the race baffles. Cover the entire baffle as seen in photo below.


19. Use the provide teflon tape to hold the packing in place as seen in photo below.


20. Looking at the oval angled end, slid the packing material down 2" as seen in photo below.

 

21. Trim the extra packing material off the back end as seen in photo below.

22. Insert the covered baffle into the muffler can. The top part of the slanted baffle goes towards the top of the muffler can.

23. This is what the inserted baffle should look like.

24. Insert the aluminum baffle plate as seen in photo below.

25. Slide the plate all the way down. Make sure all screw holes are visible through the rivet holes. If you don't see a hole on the narrow side, flip the baffle plate.

26. Reinstall end cap. Make sure the angle end is facing downward.

27. Using a small screw driver or pick, align the baffle plate with the screw holes. See photos below for reference.

28. Install hex head screws and tighten into place. Do not over tighten the screws, you will strip the aluminum plate.

29. Congratulations, you are finished. Reinstall the mufflers and get ready for the new sound and performance gains.